Tufted rug and method of making the same



Nov. 14, 1933. E. JOHNSON 1,935,320

TUFTED RUG AND METHOD OF MAKING THE SAME Filed May 27, 1952 iii 122 07? I %/%6/ im Patented Nov. 14, 1933 UNITED STATES 1,935,320 TUFTED RUG Ago METHOD or MAKING SAME Elmer Johnson, Oshkosh, Wis., assignor to Waite Carpet Company, Oshkosh, Wis., a corporation of Wisconsin Application May 27, 1932. Serial No. 613,805

6 Claims.

The method of the present invention is directed to the tufting of rugs by the formation of lines of stitching'which are' produced on a tufting machine of a character well understood in the art.

In tufting rugs in this manner, it has been customary in the past to run the lines of stitching in the form of closely spaced parallel rows which, in most cases, resulted in the production of a rug having a. ribbed appearance although 10 where very fine yarn or rayon silk was employed and the lines of stitching were spaced very close together, the ribbed appearance was not pronounced.

The method of the present invention involves a modification or variation of the customary practice in that, for most purposes, the parallel lines of stitching are spaced a relatively greater distance apart than is customary, and the lines of stitching running in one direction are traversed by lines of stitching crossing at right angles with the result that the tufting of the rug, instead of presenting the appearance of rows or ribs, presents rather the appearance of group tufts of a square formation, it being understood, however, that by reason of the nature of the materials employed, the tufts merge more or less into one another although the general effect produced is that of squares lying in closely spaced and more or less merging relation to one another.

The method of cross-stitching permits of variations in design as well as in the texture of the rug surface by reason of the fact that the crossstitching may be applied in a way which will break up the appearance of continuity of lines in the tufted surface of the rug so that pattern effects in contrasting colors presenting the appearance of interspersed patches of color, or broken line effects, can be produced and numerous variations in appearance can be secured, which were impossible in the case of tufted rugs produced in the usual mannerl Furthermore, the method of tufting is one which permits continuous line effects to be associated with broken or variegated efi'ects since it is a characteristic feature of the present invention that where a line of tuft stitching is run continuously through a previously formed ground work of tufted stitching, the line last stitched will displace the previous tufting sufliciently to present the effect of a continuous or unbroken line.

Where it is desired to secure broken line ef fects in tuft stitching running-in both directions, I find that these effects can be produced by a method which comprises, first, the formation of doubly spaced parallel lines running longitudinally, followed by the, formation of doubly Spaced parallel lines running transversely, after which the intermediate lines are stitched longitudinally and finally the intermediate lines are stitched transversely which produces the semblance of an in and out or woven effect as viewed from the reverse side of the rug with a corresponding breaking up in the continuity of both the longitudinal and transverse lines of stitching on the tufted side of the rug with the exception of the last laid line of stitching which runs continuously. By the employment of such methods of interspersing the longitudinal and cross lines of tuft stitching, and by the use of lines of stitching in contrasting colors running continuously through the crisscross lines of stitching, I am able to secure numerous variations in border and pattern effects which cannot be secured in the ordinary manner and which give to the completed rug a characteristic group tufted appearance which clearly distinguishes it from rugs produced in the usual manner.

In order to more fully disclose the details of the present method, and the characteristics of the rug produced thereby, reference is made to the accompanying drawing wherein Fig. 1 is a plan view of a rug showing a typical or characteristic pattern effect produced by the method of the present invention;

Fig. 2 is an enlarged detafl of the tufted front side of the rug indicating in a general way the square tufted appearance produced by the crisscross stitching and showing further how use may be made of contrasting colors to produce a mottled or variegated effect.

Fig. 3 is a view of the reverse side of the rug showing the crisscross lines of stitching; and

Fig. 4 is a detail showing how the individual tufts are formed.

In carrying out the method of the present in- 95 vention, and subject to variations in detail, the rug is produced by applying to a canvas or similar backing 10, a series of longitudinal alternate rows of stitching 11 which are doubly spaced and are next followed in order of sequence by doubly 100 spaced rows of cross stitching 12 which break through or interrupt the longitudinal rows 11 at the points of intersection. Thereafter, the intermediate rows of longitudinal stitching 1111 are formed which break through the cross rows 12 5 at the points of intersection, and the rug is finally completed by cross rows 120 which in turn break through the longitudinal rows lla'at the points of intersection. If more complicated effects are desired, they can be obtained by an 110 elaboration or continuation of the method described above, each row of stitching when applied breaking through the preceding rows which it intersects, so that in every case the rows of stitching last laid will present the appearance of continuous lines, and all preceding rows will be intersected in greater or less degree, depending upon the nature of the pattern chosen and the order of sequence in laying the rows of stitching.

In producing such a rug, the operator first runs the lines of tuft stitching 11 longitudinally of the backing and spaced apart a distance equal to twice the spacing required in the completed rug. After running the alternate longitudinal rows, the rug is repositioned to run the alternate rows of stitching 12 crosswise of the rug and spaced apart twice the distance intended in the completed rug. The rug is thereafter repositioned to stitch in the intermediate longitudinal rows 11a and finally re-positioned to stitch in the intermediate cross-rows 12a.

It will be observed that this method of stitching results in an interspersion of the rows in such a manner that the ribbing effect produced by running rows of tuft stitching continuously in one direction is broken up by the cross-stitching at right angles thereto. If all of the cross-stitching were applied after the rug had been completely stitched in the longitudinal direction, the result would be to give the appearance of continuity to the rows of cross-stitching last applied and to break up the continuity of the longitudinal rows, and while this result is of minor importance where a single color is employed, it materially changes the appearance of the completed rug where variegated colors are employed in which latter case a proper interspersion of the colors requires that the alternate method in the application of the lines of stitching be employed. Of course, it will be understood that for the purpose of variation in design, it may be desirable to provide several continuous rows of longitudinal stitching without breaking up the same by cross stitching, and where the rib effect is desired in the design, the longitudinal lines of stitching can be more closely spaced and the cross-stitching omitted in that portion of the rug where the rib effect is alone preferred with the cross-stitching applied to those portions in which the square tufting effect is to be given due prominence. Pleasing variations in design can be produced by the use of continuous lines of stitching at or near the border of the rug with the interspersed cross-stitching in the center portion of the rug.

In the same manner, single rows of stitching last applied to the rug will produce continuous lines or pattern effects breaking through the previously applied lines of stitching and thus accentuated in appearance to stand out as a design or pattern from the body of the rug. Further variations in design can be secured by running the longitudinal and/ or cross-stitching only part way of the rug and/or by continuing a row of stitching in a different and contrasting color so that it will be understood that the present invention which is directed mainly to the use of crossstitching can be used in numerous combinations which serve to vary not only the appearance of the rug, but the resulting texture of the tufted or piled surface.

As indicative of the nature of the surface effects produced by the cross-stitching, reference is had to Fig. 2 which shows the surface roughly divided up into tufted squares 13. The tufted squares may be formed in color patterns as indicated the areas 14 and 15 to give to the completed rug a checkerboard pattern throughout the areas where this manner of tufting is observed. Where contrasting colors are employed, the tuft squares of one color will be interposed through the tuft squares of the contrasting color in a more or less clearly defined pattern effect, although it will be understood from the nature of the materials employed and the depth of the piling produced that the square tufting effect is more or less approximated and that the square tufts are not individually clearly defined, although in the completed rug the tufting effect is quite clearly apparent. The somewhat irregular variegated effect shown in the rows 14 is secured by the use of yarns of contrasting color in the lines of stitching which cross each other, so that the continuity of the lines is interrupted in greater or less degree, although the resultant effect within relatively small areas is rather of a mottled appearance than of a regularly subdivided pattern. In the present instance, the areas 14 are formed in part by continuous lines of dark stitching which also produce the areas 15, but within the areas 14 the dark lines of stitching are intersected by lines of light stitching which give the variegated color,

effect noted. Where it is desired to superpose a clearly defined line 16 in contrasting color, such line can be stitched last and the tufts thus produced will displace the previously formed tufts sufficiently to give continuity and prominence to the line effect or to any other desired patterned effect which is intended to stand out prominently from the rug surface.

Although for most purposes the cross stitching will be applied at right angles to the longitudinal stitching, it will be understood that it is not theintention to limit the invention to the right angle transverse arrangement shown, since similar effects can be produced where the lines of stitching traverse one another in other than right angle relationship, and similarly additional and more complicated effects can be produced by various combinations of stitching which can be laid over the criss-cross arrangement here particularly illustrated, with a variable interspersion of the lines of stitching over and under one another, in order either to give continuity to the line effect where desired or to give a broken effect, or such combinations of the two as may be desired.

It will therefore be understood that the principles involved in the present invention may be amplified or complicated by various combinations, and that the rug herein particularly described exemplifies a relatively simple application of the principles underlying the present invention.

Furthermore, with the use of the same color combinations, and with rugs in which the lines of stitching are otherwise similarly arranged, variations in detail can be introduced by the mere expedient of choice in the lines of stitching to be last applied, it being understood that the last line of stitching will produce a continuous line effect, which serves to break up or intersperse the tufted effect produced by previously applied lines of stitching, so that in this manner, with the use of contrasting colors, the desired prominence can be given to the chosen color, and clearly pronounced square or other patterned effects produced, with numerous variations in detail.

Thus, where it is desired to produce a rug in clearly defined squares or other configured patches, the ultimate lines of stitching can be produced in such colors as will serve the purpose of giving ell-0h accentuated color lines as may be necessary to delineate the areas of the intended character. Similarly, where a lesser degree of demarcation is required, the division lines can be more or less broken or interrupted by subsequently applied cross lines of stitching, which serve to interrupt the continuity of the division lines, and thus produce patterned effects of a less clearly defined or differentiated character.

It will therefore be understood that the present description serves merely by way of exemplification of the means provided for securing a multiplicity of variations in pattern effect within the skill and judgment of the designer, and that all variations in the manner of overlying or underlying intersecting lines of stitches, for the purpose of producing patterned effects of the general character described, are intended to come within the scope of the present invention as d fined in the accompanying claims.

Furthermore, the rug itself, aside from the patterned effect produced in the manner described, possesses a distinct or characteristic feel which is due to the grouping or lumping of the tufts at the points of intersection, with the result that the rug possesses the feel of a heavier rug than it would be possible to produce if the same amount of yarn were used with the lines of stitching all running in a single direction. It is thus characteristic of this rug that the pile surface is presented in the form of group tufts or patches rather than ribs or lines, which gives to the pile surface a distinct appearance, irrespective of patterned effects due to the use of contrasting colors.

The individual tufts 17 are formed in the manner indicated in Fig. 4, on a special form of sewing machine well understood in the art, which applies lines of stitching to the backing material and cuts the loops thus applied to formeupstanding tufts, and it will be understood that the square tuft groups 13 previously described are the resultant of a massing together of the individual tufts radiating more or less from the points of intersection of the longitudinal and cross-stitching applied as previously described. It will further be understood that where reference is made to square grouped tufts, it is intended to cover any grouping produced in the manner indicated, which approximates a square formation as distinguished from continuous rows of tufts which give a ribbed effect to the completed rug.

The invention is one which may be used in the production of bath mats, chair seats, or other forms of tufted material, and variations in the spacing of the rows of stitching will correspondingly vary the smoothness and compactness of the tufted surface, depending upon the use for which the completed article is required, so that where reference is made to a rug, it willbe understood that this term is intended to include other articles of rug-like character, or even upholstery or the like.

I claim:

1. The method of making an ornamental pile fabric or rug which comprises: first the running of a first series of rows of substantially parallel tuft producing stitching through a base fabric in predetermined direction, each stitch affording an upstanding outwardly spreading out tuft and in spacing said rows from one another a multiple of the intended distance between rows in the completed rug; second in running a second series of rows of parallel tuft stitching of like character transversely through the rows of the first series and thereby displacing the tufts thereof at the points of intersection; third in running a third series of rows of tuft stitching of like character parallel with the rows of the first series and in intervening relation thereto and thereby displacing the tufts of the second series-rows at the points of intersection; and fourth in running a fourth series of rows of tuft stitching of like character parallel with the rows of the second series and in intervening relation thereto and thereby displacing the tufts of the first and third series-rows at the points of intersection; the stitch spacing and the row spacing observed in the respective rows of tuft stitching being such as to cause the spread tips of the tufts throughout the rug to contact one another and conceal the base fabric and. afford an allover pile surface, and the individual tufts at the points of intersection of the rows of tuft stitches being more densely crowded together to reinforce one another against matting down and form contigous evenly spaced group-tufts affording a characteristic texture and appearance in the com pleted rug.

2. The method of making an ornamental pile fabric or rug which comprises: first the running of a first series of rows of substantially parallel tuft producing stitching through a base fabric in predetermined direction, each stitch affording an upstanding outwardly spreading cut tuft and in spacing said rows from one another a multiple of the intended distance between rows in the completed rug; second in running a second series of rows of parallel tuft stitching of like character transversely through the rows of the first series and thereby displacing the tufts thereof at the points of intersection; third in running a third series of rows of tuft stitching of like character parallel with the rows of the first series and in' intervening relation thereto and thereby displacing the tufts of the second seriesrows at the points of intersection; and fourth in running a fourth series of rows of tuft stitching of like character parallel with the rows of the second series and in intervening relation thereto and thereby displacing the tufts of the first and third series-rows at the points of intersection; the stitch spacing and the row spacing observed in the respective rows of tuft stitching being such as to cause the spread tips of the tufts throughout the rug to contact one another and conceal the base fabric and afford an allover pile surface, and the individual tufts at the points of intersection of the rows of tuft stitches being more densely crowded together to reinforce one another against matting down and form contiguous evenly spaced group-tufts affording a characteristic texture and appearance in the completed rug, contrasting colors being employed in the tuft stitching of selected series of rows to afford recurrent color effects in the pattern of the rug pile, and the color of the last run rows of tuft stitching being selected to afford unbroken line effects in the pattern.

3. The method of making an ornamental pile fabric or rug which comprises: the running of rows of substantially parallel tuft producing stitching through a base fabric in predetermined direction, each stitch affording an upstanding outwardly spreading out tuft; and in running parallel rows of tuft stitching of like character transversely through the first mentioned rows, the spacing observed in running the respective rows of stitching being such as to spread the tips of the tufts throughout the rug to contact one another to conceal the base fabric and afford an alloverpile surface, and the individual tufts at the points of intersection of the rows of tuft stitches being more densely crowded together to reinforce one another against matting down and form contiguous group-tufts affording a characteristic texture and appearance in the completed rug.

4. A tufted rug of the class described comprising a base fabric carrying a first series of substantially parallel rows of tuft stitching running in a predetermined direction, each stitch affording an upstanding outwardly spreading cut tuft, and the base fabric also carrying rows of parallel tuft stitching of like character running transversely through the rows first mentioned, the spacing observed in the stitches of each row and between the rows themselves being such as to cause the spread tips of the tufts throughout the rug to contact one another to conceal the base fabric and afiord a pile surface, and the individual tufts at the points of intersection of the rows of stitching being more densely crowded together and reinforcing one another against matting down and forming contiguous group-tufts affording a characteristic texture and appearance in the completed rug.

5. A tufted rug of the class described comprising a base fabric carrying a first series of rows of substantially parallel tuft stitching running in a predetermined direction, each stitch affording an upstanding outwardly spreading out tuft and said rows being spaced from one another a multiple of the intended distance between rows in the completed rug, the base fabric carrying a second series of parallel rows of tuft stitching of like character running transversely through the rows of the first series and displacing the tufts of said first series at the points of intersection, and the base fabric carrying a third series of parallel rows of tuft stitching of like character running parallel with the rows of the first series and in intervening relation thereto and traversing and displacing the tufts of the second series, and the base fabric carrying a fourth series of parallel rows of tuft stitching of like character running parallel with the rows of the second series and in intervening relation thereto and intersecting and displacing the tufts of the first and third series, the

spacing observed in the stitching being such as to cause the spread tips of the tufts throughout the rug to contact one another to conceal the base fabric and afiord a pile surface, and the individual tufts at the points of intersection of the rows of stitches being more densely crowded together to reinforce one another against matting down and form contiguous group tufts affording a characteristic texture and appearance in the completed rug.

6. A tufted rug of the class described comprising a base fabric carrying a first series of rows of substantially parallel tuft stitching running in a predetermined direction, each stitch affording an upstanding outwardly spreading out tuft and said rows being spaced from one another a multiple of the intended distance between rows in the completed rug, the base fabric carrying a second series of parallel rows of tuft stitching of like character running transversely through the rows of the first series and displacing the tufts of said first series at the points of intersection, and the base fabric carrying a third series of parallel rows of tuft stitching of like character running parallel with the rows of the first series and in intervening relation thereto and traversing and displacing the tufts of the second series, and the base fabric carrying a fourth series of parallel rows of tuft stitching of like character running parallel with the rows of the second series and in intervening relation thereto and intersecting and displacing the tufts of the first and third series, the spacing observed in the stitching being such as to cause the spread tips of the tufts throughout the rug to contact one another to conceal the base fabric and afford a pile surface, and the individual tufts at the points of intersection of the rows of stitches being more densely crowded together to reinforce one another against matting down and form contiguous group-tufts affording a characteristic texture and appearance in the completed rug, contrasting colors being employed in the stitching of selected series of rows to afford recurrent color effects in the pattern of the rug, and the coloration of the last laid rows of stitching being selected to afford unbroken effects.

ELMER JOHNSON. 

